Effective precautions for "terminal withdrawal" in harness failure mode

Wiring harness automobile consists of terminals, sheaths, wires, connectors, tapes, bellows, PVC pipes, heat-shrinkable tubes, fuses, fuse boxes, and other accessories, which play the role of the neural network of the whole car, transmit signals, and execute electrical energy. Because of the different roles of wiring harness in the whole car, it can be divided into engine harness, front harness, instrument harness, chassis harness, door harness, top harness and so on. Wiring harness is the neural network system of the car, which is responsible for transmitting voltages, signals and a large amount of data during the operation of the whole car. Especially in the context of the Internet and big data, not only does it require the wiring harness carrier to play the role of pass-through, but it also puts forward higher requirements for data transmission rate and response capability. At the same time, due to the limited physical layout space of the harness, it brings more challenges to its after-sales maintenance. Terminal withdrawal is a common failure mode for wiring harnesses. The withdrawal of a pin means that the terminal does not reach its intended position, thereby disabling the connector's function. Harness carts are primarily operated manually, which can be difficult to maneuver. In order to better prevent and control terminal pin withdrawal problems, the following aspects are controlled:design selection, process protection, terminal crimping, assembly, electrical testing, and assembly.

There are two factors affecting terminal debouncing:one is the deformation of the shrapnel, and the other is the terminal offset. Both are subject to external forces in the process, resulting in terminal deformation. In order to protect the terminal shrapnel from deformation by foreign objects, terminal crimping bixu with a protective cup to protect the terminal head, the protective cup can only be removed after assembly. After the wiring harness assembly is completed, the male end of the sheath should be sealed with a sealing tape or guard to prevent the terminal from being skewed by foreign objects in the transportation process. Terminal crimping is a key part of the automotive wiring harness production process. The main process is to connect the electrical system to the terminals and combine the terminals with the circuit through machine tool technology. Terminal crimping is also an influencing factor for terminal de-pinning in the wiring harness production process. "Banana" terminals are a common problem in the terminal crimping process, caused by crimping mold problems. Terminal bending crimp assembly, connector insertion and extraction force zengda, and heavier, the male terminal can not be inserted into the effective area of the female terminal, the terminal pin exit. Adjust the limit pin on the crimping equipment can solve such problems. Wire harness assembly mainly by manual operation. In order to better reduce the risk of terminal assembly is not in place, the industry generally follow the principle of "a plug two listen to three pull". A plug is to insert the terminal, two listening is to listen to the sound of the terminal inserted in place, three pull is to pull the terminal to see if it is inserted out. An employee inserts the terminal thousands of times, easy to operate fatigue. In order to better allow employees to form muscle memory, we have made adjustments. Take a break "pull". Pulling here means setting up a tension machine at the operating position. Before and after the start of the class, employees need to pull the dynamometer with their hands to ensure that the staff's insertion strength, the formation of muscle memory; dier kind of "a look, two insertion, three listening, four pull". Add a "glance" to identify the terminal deformation and banana terminals, thus ensuring that the insertion of the insertion direction is correct. Harness electrical test here is a very important check point for the harness to do. In order to ensure that the terminal skew and can effectively identify and intercept the terminal back pin, electrical test equipment needs to meet the following conditions: First, the male terminal fixture bixu wear anti-skew grid (Figure 12), to ensure that the skewed terminal can not be conduction; Second, the electrical test probes using threaded ladder needle, can effectively prevent the terminal in the process of electrical testing was launched. Third, according to the dimensional chain to calculate the amount of movement of the terminal in the sheath, so as to make the probe, the development of the probe's routine maintenance program.

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